Process of preparing a detergent



. ing the alkali metal sub'silicate.

Patented Nov. l 2,l9 46 PROCESS OF raErAnmG A DETERGENT oomosmon Edwin S. Garverich, Upper Darby, and William L. Martin, Philadelphia, Pa... assignors to The Pennsylvania Salt Manufacturing Company,

corporation of Pemmyl- Philadelphia, Pa., a

vania No Drawing.

2 Claims. 1

This invention relates to improved laundry detergent and break, compositions and to their preparation. v

Particularly the invention relates to the preparation of detergent compositions containing ingredients which will react with one another.

For example, detergent compositions made by mixing together alkali metal silicates such as sodium orthosilicate, sodium sesquisilicate and sodium metasilicate; hydrophillic colloids, such as bentonite; alkali metal phosphates such as the sodium orthophosphates, the sodium pyrophosphates and sodium metaphosphate; and fatty acid containing oils such as tall oil, or fatty acidester oils, such as palm oil, have been found by us to be particularly effective when mixed in certain proportions and order under certain conditions.

According to this invention laundry detergent and break compositions are prepared from materials such as above mentioned in such manner that substantial reaction between the alkaline materials and the clay, on the one hand, and alkaline materials and fatty acid containing oil on the other, is prevented.

An important characteristic of an embodiment of this invention resides in the order of mixing the components. A composition consisting of an alkali metal subsilicate, an absorptive clay, an alkali metal phosphate and fatty acid is prepared so that no appreciable reaction will take place between the fatty acid and silicate, or between the clay and the silicate. If these reactions are not prevented, the properties of the product will be impaired, the quality will be relatively poor, and the oil will be saponified by reaction with the alkali metal silicate. This is accomplished by adsorbing or absorbing substantially all of the fatty acid in the clay before add- In this manner substantial reaction of the fatty acid or oil and silicate and the clay and silicate is prevented.

Control of moisture is essential during processing if reaction between the alkali metal subsilicate and the clay is to be controlled. One control is exercised by the premixing or the oil and bentonite, already described, thereby preventing the formation of free moisture through saponincation when the alkalies are added to the mix. An advantage of preventing saponification is that it will then occurwhen the composition is added to water and this is known to produce a greater cleaning effect. "en soap is termed in the wash wheel, a greater cleaning eflect is produced at the moment or neutralization Application December 4, 1942, Serial No. 468,168 1 I by pre-drying the bentonite or adsorptive'clay.

A further reaction control is carried out by cooling during the mixing of the constituents as well as coolingthe final product immediately after its preparation. Cooling during mixing removes the heat of any reaction which does occur preventing an acceleratedand uncontrollable reaction. Cooling of the product, as formed, will arrest any reaction then taking place thereby further preventing heat generation from promoting reaction between the unreacted clay and alkali metal subsilicate and between the oil and alkali metal subsilicate.

As stated, it is important that the tall oil or fatty acid be mixed with the absorptive clay before the alkali alkali subsilicate is added. I! desired, it is within the scope of the invention to eflect mixing in any other order. In such case, more cooling to prevent reaction will be necesity as when prepared according to the preferred I mixing order.

By first mixing the clay and oils there are obtained the following advantages:

1. Better and more uniform distribution of the OilS. 3

2. Prevention of an appreciable reaction between the clay and alkali subsilicate.

3. Retardation of saponiflcation of the fatty acids until the composition is added to water, for example in the laundry wash wheel.

4. A uniform and better appearing product.

The preparation of the composition of this invention is generally carried out by feeding the oils, preferably as an atomized spray. into a mixer in which the clay is being agitated. After addition of the oils, the alkalimetal subsilicates and alkali metal phosphates are added. The mixer is so arranged that sumcient heat dissipation will occur to prevent a substantial rise in temperature and so that compression and compaction of the ingredients will be at a minimum. After the ingredients have been thoroughly mixed, the product is cooled, preferably with agitation, to ensure substantially complete arresting of any reaction which may be taking place and to break up any agglomerates or nodules which may be in the product. This step may be carried out in a flight conveyor equipped with cooling jackets or in a cooled rotary tube or in any other man ner. I

s 3 The following examples will serve to illustrate the compositions of the invention.

The relative quantities or ingredients employed in the composition will vary somewhat depending upon conditions of use.

The bentonite or adsorptive clay may be from 25% to 75% of the mixture.-

The quantity oi oils used may be varied. From about 5% to 20% will yleldeflective, detergent results. recommended and. amounts in excess about 25% lead to a material diflicult to process and to such general disproportions that the composition will not yield good results.- Obviously, as shown inExample' 2 some oi-the iatty acids may Greater quantities are not generally be added in the form varied. The use 01' about 25%45% isgenerally sufficient. Quantities greater than about 45% .trouble, disproportionate relationship between alkali and colloid, excessive pH values in the break operation and, therefore, poor results.

Wherever.allrali metal silicate is used in the specification these compounds or mixtures are encompassed within the term which have a ratio. of NazO-to-SiOz of 1 to 1 or greater. This in 'cludes-Ssodiummetasilicate, the subsilicates soabsorption r the oil by the clay and then ad-' e Parts by weisht Bentonite (200 mesh) 40 Tall oil (refined) a Sodium orthosilicate 85' Trisodium phosphate (monohydrate) Bentonite v 40 Tall oil (crude) 7.5

' Red oil (oleic acid) 1.5.

Sodium orthosilicate .l. 35 v Trisodium phosphate (monohydrate) 10 Bentonite I 45 Tall nil v Sodium orthosilicate Trisodium phosphate"-.. 5

Bntonite (200 mesh) Tall oil (refined) 15 "Sodium orthosilicate' 85.:

. 5 Bentonite (200 mesh).-.. 35 Tall oil (refined) '15. Sodium metasilicate. 40 Trisodium phosphate (monohydrate).'. l0

Bentonite v I Tall oil (refined)-.. 15 Sodium sesquisilicate 35 Trisodium phosphate -4.- 5

dium sesquiand sodium orthosilicate, and-mixtures oi, caustic and silicates inwhich the over all ratio at NaaO to 810: is'l to 1 or greater. v v.

The alkali metal phosphate content may be doubled' zor even tripled, but use of less than ab0ut 5.%-.'. will lead to serious losses in suds stability and "level. It is important that a phosphate of lowi inoisturecontent be used for goodresults.

1. Theprocess or preparing a detergent composition containing by weight 5%-25%' tall oil,

25% -45,%" oi. an alkali metal subsilicate capable or. saponiiying said oil, at least 5% oi. analkali metal phosphate and'25%-75% or bentonlte which comprises mixing the oil and clay to cause mixing the alkali-metal subsilicate; and wherein at least. the} admixing oi the subsllicate is eilected durinj booling'; and further cooling the product formed.

2. The process of preparing a detergent composition containing about 5m 25 parts by weight tying said on, at least 5% of an alkali metal phosphate and about 25 to '75 partsby weight of an 'rne' alkali metal subsilicate can likewise be 

